Customer Profile
A leading manufacturer of industrial valves for gas applications serving the medical, automotive, and general industrial sectors. The company specializes in Ultrahigh-Purity (UHP) and High-Purity (HP) components, where precision, cleanliness, and surface integrity are crucial to product performance and compliance standards.
Challenges
The manufacturer previously relied on abrasive flow machining to finish internal valve channels. However, this method posed several limitations:
- High capital investment and operational costs due to specialized tooling and consumables.
- Inability to process more than one part at a time, resulting in inefficient throughput.
- Inconsistent surface finishes, particularly within blind holes and intricate internal geometries.
- Despite achieving a surface roughness of approximately 0.05 µm Ra, additional passivation was still required to meet purity standards.
Solution
To address these challenges, the company adopted DLyte Dry Electropolishing Technology using the DLyte PRO500 system. The new finishing process was integrated into a three-stage automated workflow comprising machining, dry electropolishing, and cleaning. This setup allowed simultaneous polishing of 64 valve components per batch in just 29 minutes, ensuring full internal coverage and uniform finishing even in complex geometries.
Impact
The implementation of DLyte technology transformed the manufacturer’s finishing workflow:
- Achieved best-in-class concerning surface roughness (Ra under 0.05 micrometers)
- Geometry and tolerance preservation & homogeneous results across the piece
- Eliminated the need for multistep processes.
- Reduced production time and costs while increasing throughput.
- Enabled a scalable and repeatable polishing process
Discover the key benefits and features of DLyte Electropolishing Systems or Contact Us for product sales quote.
Source : DLyte
